Surgical instrument with articulation mechanism

ABSTRACT

A surgical instrument for surgically joining tissue is disclosed. The instrument comprises a handle assembly, an elongated portion, an end effector, and an articulation mechanism. The elongated portion extends distally from the handle assembly. The end effector is disposed adjacent a distal portion of the elongated portion. The articulation mechanism is disposed in mechanical cooperation with the end effector for articulating the end effector. The articulation mechanism comprises a lever, a knob, a plate and a lower clutch. The plate is disposed at least partially within a portion of the knob. The lower clutch is disposed in mechanical engagement with the plate. The plate is disposed at least partially between the lower clutch and the knob. The lower clutch is keyed to the plate to limit rotation therebetween. The lower clutch is keyed to the knob to limit rotation therebetween.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 15/376,003, filed Dec. 12, 2016, which is a continuation of U.S. patent application Ser. No. 13/849,572, filed Mar. 25, 2013, (now U.S. Pat. No. 9,526,497), which claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 61/643,389, filed May 7, 2012, the entire disclosure of which is incorporated by reference herein.

BACKGROUND Technical Field

The present disclosure relates generally to instruments for surgically joining tissue and, more specifically, to surgical instruments capable of articulation and articulation mechanisms for use therewith.

Background of Related Art

Various types of surgical instruments used to surgically join tissue are known in the art, and are commonly used, for example, for closure of tissue or organs in transection, resection, anastomoses, for occlusion of organs in thoracic and abdominal procedures, and for electrosurgically fusing or sealing tissue.

One example of such a surgical instrument is a surgical stapling instrument, which may include an anvil assembly, a cartridge assembly for supporting an array of surgical staples, an approximation mechanism for approximating the cartridge and anvil assemblies, and a firing mechanism for ejecting the surgical staples from the cartridge assembly.

Using a surgical stapling instrument, it is common for a surgeon to approximate the anvil and cartridge members. Next, the surgeon can fire the instrument to emplace staples in tissue. Additionally, the surgeon may use the same instrument or a separate instrument to cut the tissue adjacent or between the row(s) of staples.

SUMMARY

The present disclosure relates to a surgical instrument for surgically joining tissue. The instrument comprises a handle assembly, an elongated portion, an end effector, and an articulation mechanism. The elongated portion extends distally from the handle assembly. The end effector is disposed adjacent a distal portion of the elongated portion. The articulation mechanism is disposed in mechanical cooperation with the end effector for articulating the end effector. The articulation mechanism comprises a lever, a housing, a plate and a lower clutch. The plate is disposed at least partially within a portion of the housing. The lower clutch is disposed in mechanical engagement with the plate. The plate is disposed at least partially between the lower clutch and the housing. The lower clutch is keyed to the plate to limit rotation therebetween. The lower clutch is keyed to the housing to limit rotation therebetween.

In disclosed embodiments, the plate is rotatable with respect to the housing prior to engagement between the lower clutch and the plate.

In disclosed embodiments, the lower clutch is keyed to the plate via four keys.

In disclosed embodiments, the lower clutch is keyed to the housing via two keys. Here, it is disclosed that the two keys used to key the lower clutch to the housing are also used to key the lower clutch to the plate.

In disclosed embodiments, the articulation mechanism further comprises a cover disposed in contact with the lever, a biasing element disposed in mechanical cooperation with the cover, and an upper clutch disposed in mechanical cooperation with the lower clutch and in mechanical cooperation with the biasing element. Here, it is disclosed that the distance the upper clutch can move with respect to the housing due to compression of the biasing element is distance “a,” a radial edge of the cover is spaced from the lever a distance “b,” the lower clutch is keyed to the housing via at least one key, the key having a distance “c” disposed in the same direction as distances “a” and “b,” and the distance “c” is greater than the distance “a” plus distance “b.”

In disclosed embodiments, the articulation mechanism comprises a drive element disposed in mechanical cooperation with the housing. A shaft of the drive element extends through apertures of the plate and the lower clutch. The shaft is mechanically coupled to the lever. Here, it is disclosed that the articulation mechanism further comprises an articulation shaft disposed in mechanical cooperation with the drive element, such that rotation of the drive element causes translation of the articulation shaft along the first longitudinal axis.

The present disclosure also relates to an articulation mechanism for use with a surgical instrument. The articulation mechanism comprises a lever, a knob, a lower clutch disposed in mechanical cooperation with the knob, a cover disposed in contact with the lever, a biasing element disposed in mechanical cooperation with the cover, and an upper clutch disposed in mechanical cooperation with the lower clutch and in mechanical cooperation with the biasing element. The distance the upper clutch can move with respect to the knob due to compression of the biasing element is distance “a,” a radial edge of the cover is spaced from the lever a distance “b,” the lower clutch is keyed to the knob via at least one key, the key having a distance “c” disposed in the same direction as distances “a” and “b,” and the distance “c” is greater than the distance “a” plus distance “b.”

In disclosed embodiments, the articulation mechanism further comprises a plate disposed between the knob and the lower clutch. Here, it is disclosed that the lower clutch is keyed to the plate to limit rotation therebetween. It is further disclosed that the plate is rotatable with respect to the knob prior to engagement between the lower clutch and the plate. It is further disclosed that the lower clutch is keyed to the plate via four keys.

In disclosed embodiments, wherein the lower clutch is keyed to the knob via two keys. Here, it is disclosed that the articulation mechanism further comprises a plate disposed between the knob and the lower clutch. The two keys used to key the lower clutch to the knob are also used to key the lower clutch to the plate.

In disclosed embodiments, the articulation mechanism further comprises a drive element disposed in mechanical cooperation with the knob. A shaft of the drive element extends through an aperture of the plate, and the shaft is mechanically coupled to the lever. Here, it is disclosed that the articulation mechanism further comprises an articulation shaft disposed in mechanical cooperation with the drive element, such that rotation of the drive element causes longitudinal translation of the articulation shaft.

BRIEF DESCRIPTION OF FIGURES

Various embodiments of the presently disclosed surgical instrument are disclosed herein with reference to the drawings, wherein:

FIG. 1 is a perspective view of a surgical stapling instrument with its jaw members in a linear orientation in accordance with the present disclosure;

FIG. 1A is a perspective view of the surgical stapling instrument of FIG. 1, with its jaw member in an articulated orientation;

FIG. 2 is a perspective view of an articulation mechanism of the surgical stapling instrument of FIG. 1;

FIG. 3 is a perspective, assembly view of the articulation mechanism of FIG. 2;

FIG. 4 is a longitudinal cross-sectional view of the articulation mechanism taken along line 4-4 of FIG. 2;

FIG. 5 is a transverse cross-sectional view of the articulation mechanism taken along line 5-5 of FIG. 4;

FIG. 6 is a cross-sectional view of a portion of the articulation mechanism taken along line 6-6 of FIG. 10;

FIG. 7 is a perspective, assembly view of a plate and a lower clutch of the articulation mechanism of the present disclosure;

FIG. 8 is a perspective, assembled view of the plate, lower clutch and a shaft of the articulation mechanism of the present disclosure;

FIG. 9 is a perspective, assembly view including the assembly of FIG. 8 and a knob of the articulation mechanism of the present disclosure;

FIGS. 10 and 11 are plan views of the engagement between the plate and the knob of the articulation mechanism of the present disclosure;

FIG. 12 is a perspective view of a portion of the knob of the articulation mechanism of the present disclosure;

FIG. 13 is a perspective view of the plate engaged with the knob of the articulation mechanism of the present disclosure;

FIG. 14 is a perspective view of the lower clutch engaged with the knob of the articulation mechanism of the present disclosure;

FIGS. 15 and 16 are perspective views of an upper clutch of the articulation mechanism of the present disclosure;

FIGS. 17 and 18 are perspective views of a cover of the articulation mechanism of the present disclosure;

FIG. 19 is a schematic view of the articulation mechanism in a neutral position and an articulation shaft in a neutral position; and

FIGS. 20 and 21 are schematic views of the articulation mechanism in rotated positions, and the articulation shaft in advanced and retracted positions.

DETAILED DESCRIPTION

Embodiments of the presently disclosed surgical instrument, and articulation mechanism for use therewith, are described in detail with reference to the drawings, wherein like reference numerals designate corresponding elements in each of the several views. As is common in the art, the term ‘proximal” refers to that part or component closer to the user or operator, e.g., surgeon or physician, while the term “distal” refers to that part or component farther away from the user.

A surgical stapling instrument of the present disclosure is indicated as reference numeral 10 in FIG. 1. An articulation mechanism for use with the surgical instrument is indicated as reference number 100 in the accompanying figures. The depicted surgical instrument fires staples, but it may be adapted to fire any other suitable fastener such as clips and two-part fasteners. Additionally, while the figures depict a linear fastener-applying surgical instrument, other types of endoscopic surgical instruments are encompassed by the present disclosure and are usable with the disclosed articulation assembly 100. For example, further details of endoscopic forceps are described in commonly-owned U.S. Patent Publication No. 2010/0179540 to Marczyk et al., and U.S. patent application Ser. No. 12/718,143 to Marczyk et al., the entire contents of each of which are hereby incorporated by reference herein. In another example, further details of a circular fastener-applying surgical instrument are described in commonly-owned U.S. Patent Publication No. 2009/0173767 to Milliman et al., the entire contents of which are hereby incorporated by reference herein.

Generally, surgical instrument 10 includes a handle assembly 20 including a movable handle 22, an endoscopic portion 30 extending distally from the handle assembly 20 and defining a longitudinal axis “A,” and an end effector 40, including a cartridge 50 and an anvil 60, disposed adjacent a distal portion of the endoscopic portion 30. The movable handle 22 is actuatable (e.g., through successive strokes) to cause distal advancement of a drive rod, such that the drive rod engages a portion of a drive assembly, which forces at least a portion of the drive assembly to translate distally. (Further details of how actuation of movable handle 22 causes distal advancement of the drive rod are explained in U.S. Pat. No. 6,953,139 to Milliman et al., which is hereby incorporated by reference herein.) Distal movement of the drive rod, and in particular, a dynamic clamping member affixed thereto, causes an actuation sled to move distally through the cartridge 50, which causes cam wedges of the actuation sled to sequentially engage pushers to move pushers vertically within retention slots and eject fasteners towards the anvil 60. Subsequent to the ejection of fasteners from the retention slots (and into tissue), a cutting edge of the dynamic clamping member severs the fastened tissue as the cutting edge travels distally through a slot of the cartridge 50.

Additionally, a loading unit may be attachable to an elongated or endoscopic portion 30 of surgical instrument 10 of the present disclosure, e.g., to allow surgical instrument 10 to have greater versatility. The loading unit may be configured for a single use, and/or may be configured to be used more than once. Examples of loading units for use with a surgical stapling instrument are disclosed in commonly-owned U.S. Pat. No. 5,752,644 to Bolanos et al., the entire contents of which are hereby incorporated by reference herein. It is also contemplated that the articulation mechanism can be used in a surgical instrument that has a replaceable cartridge assembly in the jaws of the instrument.

Surgical instrument 10 also includes an articulation mechanism 100 for articulating the jaw members (i.e., cartridge 50 and anvil 60) of end effector 40. In particular, the jaw members, which define an axis “B” (see FIG. 1B), are movable from between a first position where axis “B” is aligned with an axis “A” defined by endoscopic portion 30 (FIG. 1) and a second position where axis “B” is disposed at an angle with respect to axis “A” (FIG. 1A).

Articulation mechanism 100 is disposed in mechanical cooperation with handle assembly 20. In the illustrated embodiment, articulation mechanism 100 is disposed on a rotation mechanism 70 of surgical instrument 10, but it is envisioned that articulation mechanism 100 could be located on or adjacent another portion of handle assembly 20. Articulation mechanism 100 is used to longitudinally translate an articulation shaft 500 (FIGS. 19-21) with respect to handle assembly 20 to cause articulation of the jaw members of end effector 40.

With reference to FIGS. 2-18, articulation mechanism 100 includes a lever 120, a knob 140, a cover 160, a biasing element 180, a washer 200, an upper clutch 220, a lower clutch 240, a plate 260, a drive element 280, a cam pin 300, and a yoke 320 (see FIG. 3). Generally, rotation of lever 120 causes rotation of drive element 280, which causes rotation of cam pin 300, thus causing yoke 320 and articulation shaft 500 to translate longitudinally to articulate the jaw members. See FIGS. 3 and 19-21. (Further details of longitudinal translation of an articulation shaft causes articulation of jaw members are explained in U.S. Pat. No. 6,953,139 to Milliman et al., which has been incorporated by reference herein.)

With particular reference to FIG. 3, an assembly view of articulation mechanism 100 is shown. A hub portion 281 of drive element 280 is positioned in contact with a raised ring 144 portion of knob 140. In the embodiment shown, the knob 140 can be used to rotate the elongated portion 30. However, in other embodiments, a housing is used in place of knob 140. Plate 260 is positioned then positioned in contact with hub portion 281 of a shaft portion 290 of drive element 280 and with raised ring 144 portion of knob 140 (discussed in further detail below) such that a shaft portion 290 of drive element 280 extends through a bore 265 in plate 260. Lower clutch 240 is positioned in mechanical engagement with an upper surface 261 of plate 260, and upper clutch 220 is positioned in mechanical engagement with an upper surface 241 of lower clutch 240. Shaft portion 290 of drive element 280 extends through a bore 245 in lower clutch and through a bore 225 in upper clutch 220. In the illustrated embodiment, washer 200 is positioned in mechanical engagement with an upper surface 222 of upper clutch 220 and around shaft portion 290 of drive element 280. Biasing element 180 is positioned in mechanical engagement with an upper surface 202 of washer and about shaft portion 290 of drive element 280. Cover 160 is positioned in mechanical engagement with an upper surface 182 of biasing element 180 and is positioned such that shaft portion 290 of drive element 280 extends through a bore 165 of cover 160. Further, a pin 130 is inserted through an aperture 121 in lever 120 and through an aperture 283 in drive element 280 for mechanical coupling therebetween.

Additional details of the assembly of engagement of the various components of articulation mechanism 100 are discussed in further detail herein. Knob 140 is securable to handle assembly 20 and/or rotation mechanism 70. Knob 140 includes a raised ring 144 including a plurality of engagement structures. Engagement structures are configured for mechanical engagement with plate 260 and lower clutch 240. Specifically, engagement structures include a plurality of retaining walls 147 disposed around an inner periphery of raised ring 144 for engagement with plate 260, and a plurality of recesses 148 defined within an upper surface 145 of raised ring 144 for engagement with lower clutch 240 (see FIGS. 9-13).

With particular reference to FIGS. 10 and 11, the engagement between plate 260 and knob 140 is illustrated. Plate 260 includes a plurality of first keys 262 configured for engagement with retaining walls 147 of knob 140 (while four first keys 262 are illustrated, plate 260 may include more or fewer than four first keys 262). In particular, plate 260 is initially positioned within raised ring 144 such that first keys 262 are disposed adjacent retaining walls 147. See FIG. 10. Next, plate 260 is rotated (e.g., in a clockwise direction (arrow “CW” FIG. 11)) such that first keys 262 travel at least partially within undercut portions 147 a of respective retaining walls 147. See FIGS. 11-13. It is envisioned that plate 260 is rotated until further rotation is physically blocked by contact made between various portions of plate 260 and knob 140 (e.g., see FIGS. 11 and 13). As can be appreciated, the engagement between first keys 262 of plate and retaining walls 147 of knob 140 prevents or limits the movement of plate 260 with respect to knob 140 along a longitudinal axis “C” as defined through drive element 280 (see FIG. 3).

With reference to FIGS. 7-9, the engagement between plate 260 and lower clutch 240, and the engagement between lower clutch 240 and knob 140 are shown. Lower clutch 240 includes a plurality of first keys 242 configured for mechanically engaging a corresponding set of second keys 264 of plate 260, and lower clutch 240 includes a plurality of second keys 244 configured for mechanically engaging recesses 148 of knob 140. With specific reference to FIGS. 7 and 8, the illustrated embodiment of lower clutch 240 includes four first keys 242 a-d configured to mechanically engage four corresponding second keys 264 a-d of plate 260. Additionally, the illustrated embodiment of lower clutch 240 includes two second keys 244 a-b (second key 244 a is part of the same structure as first key 242 a, and second key 244 b is part of the same structure as first key 242 e) configured to mechanically engage two corresponding recesses 148 a-b of knob 140. It is envisioned that, first keys 242 and second keys 244 are symmetrically disposed about lower clutch 240. Here, the symmetrical orientation of keys 242 and/or 244 help ensure proper radial orientation between lower clutch 240 and knob 140 (i.e., lower clutch 240 can properly be oriented in two positions with respect to knob 140, with each position being 180° radially offset from each other). It is also envisioned that lower clutch 240 and/or plate 260 include one key that is wider than the others, and that is configured to engage a corresponding wide recess 148 of knob 140. In this embodiment, lower clutch 240 and/or plate 260 are properly engagable with knob 140 is a single orientation.

Alignment projections 243 of lower clutch 240 are configured to engage alignment recesses 149 of knob 140 (see FIGS. 11 and 14), thus preventing rotation therebetween, and facilitating assembly of articulation mechanism 100. Further, plate 260 includes a plurality of radial recesses 263, each of which allow a corresponding alignment projection 243 to extend past plate 260 (or to be substantially aligned with plate 260 along longitudinal axis “C” (see FIG. 3)) and into engagement with knob 140.

Additionally, while FIGS. 7-9 illustrate the engagement between lower clutch 240 and plate 260 prior to plate 260 being engaged with knob 140, it should be appreciated that, in disclosed embodiments, plate 260 is engaged with knob 140 (e.g., plate 260 is rotated with respect to knob 140, as discussed above), prior to engagement between lower clutch 240 and plate 260. As can be appreciated, engagement between first keys 242 a-h of lower clutch 240 and second keys 264 a-h of plate 260 prevents or substantially prevents rotation between lower clutch 240 and plate 260. Additionally, engagement between second keys 244 a-b of lower clutch 240 and recesses 148 a-b of knob 140 substantially prevents rotation between lower clutch 240 and knob 140.

Referring now to FIG. 14, an upper portion 246 of lower clutch 240 including a plurality of serrations 248 is shown. These serrations 248 include angled walls and function to retain articulation lever 120 at a plurality of different articulated positions as will be discussed in further detail below.

Referring to FIGS. 15 and 16, upper clutch 220 includes a hub portion 222 and a base portion 224. Hub 222 includes fingers 223 extending along and adjacent bore 225. Fingers 223 are configured and dimensioned to mechanically engage slots 282 (see FIGS. 3 and 9) of drive element 280 to rotatably fix upper clutch 240 to drive element 280. Further, the engagement between fingers 223 and slots 282 allow upper clutch 240 to move axially in relation to axis “C” defined by drive element 280 (e.g., in response to force created by biasing element 180 and contact by lower clutch 240). Hub 222 is further configured to extend through bore 205 of washer 200 and at least partially through a central opening 185 of biasing element 180.

Base portion 224 of upper clutch 220 includes an upper face 227 and a lower face 226 (see FIGS. 15 and 16). Lower face 226 of upper clutch 220 is positioned in juxtaposed alignment with serrations 248 of lower clutch 240. Lower face 226 includes a plurality of spaced projections 228 configured to be received within serrations 248 of lower clutch 240. As can be appreciated, engagement between projections 228 of upper clutch 220 and serrations 248 of lower clutch 240 help releasably secure the rotational position of lever 120 with respect to knob 140 (lever is pinned to drive element 280, and drive element 280 is keyed to upper clutch 220 via the engagement between slots 282 and fingers 223, as discussed above), to thereby releasably secure tool assembly 40 at a fixed angle of articulation. Additionally, biasing element 180 is positioned to bias upper clutch 220 towards lower clutch 240. The engagement between biasing element 180 and cover 160 and/or lever 120 provides the force in the opposite direction. Further details of the structures of upper clutch 220 and lower clutch 240, and engagement therebetween, are described in commonly-owned U.S. Pat. No. 8,061,576 to Kenneth Cappola, the entire contents of which are hereby incorporated by reference herein. Further, washer 200 is shown disposed between upper clutch 220 and biasing element 180 to add strength and robustness to articulation mechanism 100, for example.

With reference to FIGS. 17 and 18, cover 160 is generally ring-shaped and includes a first (e.g., ventral) side 162 and a second (e.g., dorsal) side 172. First side 162 (FIG. 18) includes a plurality of alignment projections 166. Alignment projections 166 are configured to engage alignment recesses 149 of knob 140 (see FIG. 11), thus preventing rotation therebetween, and facilitating assembly of articulation mechanism 100. Additionally, it is envisioned that a first alignment projection 166 a is a different size from a second alignment projection 166 b, and it is envisioned that a first alignment recess 149 a is a different size from a second alignment recess 149 b. In such an embodiment, first alignment projection 166 a is configured to engage first alignment recess 149 a, and second alignment projection 166 b is configured to engage second alignment recess 149 b. The different sizes of the alignment features would ensure that cover 160 is properly positioned and radially oriented with respect to knob 140. Further, it is envisioned that cover 160 is attached to knob 140 via at least one weld “W” (see FIG. 5).

Second side 172 of cover 160 includes an arcuate, recessed track 174 extending partially around a surface 176 thereof. In the illustrated embodiment, track 174 extends through second side 172 of cover 160 to first side 162. Track 174 includes a pair of stops 178 a, 178 b at the ends thereof, and thus forms a C-like shape. Recessed track 174 is mechanically engaged by a key 122 of lever 120 (see FIG. 4).

With reference to FIG. 4, lever 120 is shown. Lever 120 includes key 122, a hand-actuatable portion 124, and a recess 126. Key 122 includes an arcuate shape and is configured to follow arcuate track 174 of cover 160. The arcuate length of key 122 is smaller than the arcuate length of track 174, thus allowing lever 120 to rotate with respect to cover 160. Further, key 122 is configured to rotate within track 174 until lateral edges of first key 122 contact respective stops 178 a and 178 b of track 174, thus preventing further rotational movement. Recess 126 is configured for engaging shaft portion 290 of drive element 280. It is envisioned that recess 126 includes a keyed surface for engaging slots 282 of drive element 280.

With reference to FIGS. 13 and 19-21, cam pin 300 and yoke 320 are shown. Cam pin 300 is engagable with aperture 285 of drive element 280 and depends downwardly therefrom. As shown, aperture 285, and thus cam pin 300, is offset from a radial center of drive element 280 (i.e., aperture 285 is radially off-set from axis “C”). Yoke 320 is disposed in mechanical cooperation with cam pin 300. More particularly, yoke 320 includes a slot 322 therein, which is configured to slidably receive a portion of cam pin 300 therein. Additionally, a distal portion of yoke 320 is disposed in mechanical cooperation with a proximal portion of articulation shaft 500 (see FIGS. 19-21). Further, yoke 320 is rotationally fixed with respect to knob 140 and is longitudinally translatable with respect to knob 140.

In use, to cause articulation of end effector 40, a user rotates lever 120. As lever 120 is rotated, drive element 280, which is pinned and keyed to lever 120, also rotates. Rotation of drive element 280 causes rotation of upper clutch 220, due to the mechanical engagement therebetween, as discussed above. As can be appreciated, the engagement between upper clutch 220, lower clutch 240, and biasing element 180, allows for a controlled rotation of upper clutch 220, and thus drive element 280. Further, rotation of drive element 280 causes cam pin 300 to rotate about axis “C,” and to travel within slot 322 of yoke 320, thus causing yoke 320 to translate longitudinally along axis “A.” Longitudinal translation of yoke 320 causes articulation shaft 500 to translate longitudinally along axis “A,” which articulates the jaw members. See FIGS. 19-21. Moreover, rotation of lever 120 in a first direction (e.g., clockwise), causes drive element 280 and cam pin 300 to rotate in the same (e.g., clockwise) direction about axis “C,” which causes yoke 320 to move in a first longitudinal direction along axis “A” (e.g., proximally), which causes the jaw members to articulate in a first direction (e.g., clockwise). Likewise, rotation of lever 120 in a second direction (e.g., counter-clockwise), causes drive element 280 and cam pin 300 to rotate in the same (e.g., counter-clockwise) direction about axis “C,” which causes yoke to move in a second longitudinal direction along axis “A” (e.g., distally), which causes the jaw member s to articulate in a second direction (e.g., counter-clockwise).

As discussed above, cover 160 may be attached to knob 140 via welds “W” (FIG. 5). The present disclosure includes features to help ensure articulation mechanism 100 is still usable even if the weld “W” connection between cover 160 and knob 140 fails. With particular reference to FIG. 5, various distances are illustrated. Distance “a” indicates the distance upper clutch 220 can move with respect to knob 140. Distance “b” indicates the distance cover 160 can move with respect to knob 140 if weld “W” fails (i.e. cover 160 can move until a radial edge thereof contacts lever 120, which is pinned to drive element 280). Distance “c” is the length of second keys 244 of lower clutch 240, which engage recesses 148 of knob 140. In the illustrated embodiment distance “c” is greater than the combined distances “a” and “b.” Thus, in situations where weld “W” fails, lower clutch 240 may move away from knob 140 up to a distance “a” plus “b,” but since the length of second keys 244 (i.e., distance “c”) is greater than distance “a” plus “b,” lower clutch 240 maintains engagement (and remains radially fixed) with knob 140. Accordingly, in such situations where weld “W” fails, rotation of lever 120 is still able to cause rotation of drive element 280 and upper clutch 220 with respect to lower clutch 240, to articulate loading unit 40. It is envisioned that distance “a” is between about 0.06 inches and about 0.12 inches. It is envisioned that distance “b” is between about 0 inches and about 0.05 inches in an embodiment. It is envisioned that distance “c” is between about 0.22 inches and about 0.23 inches in an embodiment.

The present disclosure also relates to methods of using and assembling the described surgical instrument 10 or articulation mechanism 100, as discussed above, to perform a surgical procedure, and/or to articulate jaw members of a surgical instrument.

While the above description contains many specifics, these specifics should not be construed as limitations on the scope of the present disclosure, but merely as illustrations of various embodiments thereof. For example, it is envisioned that articulation mechanism 100 is rotatable about the longitudinal axis A-A defined by endoscopic portion 30, such that rotation of articulation mechanism 100 causes rotation of the jaw members. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. 

The invention claimed is:
 1. An articulation mechanism for use with a surgical instrument, the articulation mechanism comprising: a rotatable lever; a housing having a first recess; a plate movable relative to a portion of the housing during use, the plate having a second recess; and a lower clutch having a first key and a second key, at least a portion of the plate being disposed between the lower clutch and the housing, the first key being disposed in the first recess and the second key being disposed in the second recess.
 2. The articulation mechanism according to claim 1, wherein the rotatable lever is rotatable about a lever axis.
 3. The articulation mechanism according to claim 1, wherein the first key and second key limit rotation between the lower clutch, the housing, and the plate.
 4. The articulation mechanism according to claim 1, further including a cover disposed in contact with the rotatable lever, a biasing element disposed in mechanical cooperation with the cover, and an upper clutch disposed in mechanical cooperation with the lower clutch and with the biasing element.
 5. A surgical instrument, comprising: the articulation mechanism according to claim 1, the articulation mechanism including an upper clutch disposed in mechanical cooperation with the lower clutch; wherein rotation of the rotatable lever causes an end effector of the surgical instrument to articulate with respect to a longitudinal axis defined by an elongated portion of the surgical instrument, the lower clutch being disposed between the plate and the upper clutch.
 6. The surgical instrument according to claim 5, further comprising a biasing element, the upper clutch being disposed in mechanical cooperation with the lower clutch and the biasing element.
 7. The surgical instrument according to claim 5, wherein the lower clutch has four keys.
 8. The surgical instrument according to claim 5, wherein the lower clutch includes a key engaged with a knob.
 9. The surgical instrument according to claim 8, wherein the knob rotates the elongated portion of the surgical instrument.
 10. The surgical instrument according to claim 1, wherein the plate is rotatable relative to the housing.
 11. An articulation mechanism for use with a surgical instrument, the articulation mechanism comprising: a rotatable lever; a housing having a first recess; a plate positionable at least partially within a portion of the housing, the plate being rotatable relative to the housing, and the plate having a second recess; and a lower clutch having a first key and a second key, at least a portion of the plate being disposed between the lower clutch and the housing, the first key being disposed in the first recess and the second key being disposed in the second recess. 